Arc welding system



y 1941- J. 'r. CATLETT ETAL 2,249,457

ARC WELDING SYSTEM Filed Feb. 24, 1940 Inve'n tor s: James T. Catlett Jasper E. Anderson,

x (rt/9M1, by Tm Attorney.

Patented July 15, 1941 ARC WELDING SYSTEM James T. Catlett, Scotia, N. Y.,

Anderson, Saugus, Masa, assign and Jasper E. are to General Electric Company, a corporation of New York Application February 24, 1940, Serial No. 320,594

9 Claims.

Our invention relates to electric control systems, and more particularly to arc welding systems embodying certain protective arrangements primarily intended to insur the personal safety of welding operators.

It is an object of our invention to provide an arc welding system in which normal arc welding current and voltage are conveniently available for welding without imposing unnecessary hazards on the welding operator due to prolonged open circuit or short circuit conditions in the welding circuit.

It is a further object of our invention to provide a control system in which normal arc welding current and voltage are available for a predetermined period of tim before welding, during welding, and for a predetermined period of time after a welding operation has been interrupted.

It is also an object of our invention to provide a control system in which a reduced current and open circuit voltage are available in the welding circuit before welding and in which normal arc welding current and voltage are available during welding and for a short period of time after a welding operation has been interrupted.

Further objects of our invention will become apparent from the following description thereof.

For certain arc welding operations, and particularly when using alternating current, the open circuit voltage of an arc welding circuit may be as high as 100 volts. A prolonged application of voltage of this magnitude may be physiologically dangerous to an operator, particularly under conditions of perspiration, moisture and restriction of movement frequently encountered in welding. Furthermore, short circuit conditions at the welding station are liable to dama e the welding system and are also productive of certain elements of danger to the operator because of the possibility of starting a fire when he is incapacitated and consequently not able to respond to this threat to his personal safety. Systems embodying our invention protect the operator from these personal hazards and also insures protection of the arc welding system.

In the accompanying drawing, Fig. 1 diagrammatically represents one embodiment of our invention, and Fig. 2 diagrammatically represents another embodiment thereof.

In Fig. 1, energy is supplied to a welding are established between an electrode ill and the work ll through a welding circuit i2, i3, one terminal or which is connected to the work It and the other terminal of which is connected to the electrode l through the agency of an electrode holder 14. The welding circuit l2, I3 is connected to the secondary I! of an arc welding transformer l6 whose primary I1 is connected to the source of supply i3 through conductors l9 and the contacts 20 of a contactor H. The welding transformer It may be of the usual type having a drooping voltage characteristic obtained by reason of its internal reactance.

A source of control voltage 22 is provided by the secondary 23 of a transformer 24 whose primary 25 may also be connected to the source of supply i8. The operating winding 26 of contactor 2| is connected across this control voltage through conductors 21, 23, contacts 29 or a time element relay 30, and a conductor 3|. As illustrated in the drawing, relay 30 has a delayed opening characteristic so that its contacts 23 are maintained closed for a predetermined period of time after it has been deenergized.

The operating winding 32 of time element relay 30 may be connected across control voltage 22 through conductors 21, 33 and 34, contacts 35 of auxiliary control relay 36,.conductor 31 and the contacts 33 of a switch 33. The closure of contacts 33 of switch 33 also connects the operating winding of auxiliary control relay 36 to the source of control voltage 22. The operating characteristics of relays 30 and 36 are such that relay 30 closes its contacts 23 before relay 36 opens its contacts 35.

The winding 32 of time element relay 30 may also be connected across the source of control voltage 22 through conductors 21 and 33, contacts 4| of relay 42 and conductor 43. The operating winding 44 of relay 42 is connected across the arc welding circuit l2, l3 through the contacts 45 of a relay 46 having its operating winding 41 also connected across the arc welding circuit. Relay 46 is designed to have a pick-up voltage slightly above the maximum desired arc welding voltage and relay 42 is designed to have a pick-up voltage slightly abov the minimum voltage which will sustain an arc. These relays determine the range of operating voltage for the welding arc and for convenience are hereafter referred to as maximum and minimum voltage relays.

The organization of the control system of Fig. 1 will be further described in connection with its operation.

Contactor 2| and relays 30, 36, 42 and 46 are shown in Fig. 1 in the positions they assume when deenergized. It will be noted that the welding circuit I2, i3 is deenergized because its connection with the source of supply II is interrupted at contacts 2| of contactor 2|.

When the operator is ready to start a welding operation he closes switch 2|. The closure of this switch energizes the operating winding 22 of time element relay 1| from one terminal of the source of control voltage 22 through conductors 21, 32 and 24, contacts 3|, of relay 2,6, conductor 31 and contacts 3| of switch 2| to the other terminal of the source of control voltage 22. The closure of switch 2! simultaneously energizes the operating winding 4| of auxiliary control relay 36 through conductor 81 and contacts 28 of switch 28. As noted above, however, the operating characteristics relays 3| and 2| are such that relay 36 does not open its contacts 35 until after the operating winding U of relay 30 has closed its contacts 2|. Consequently, the arrangement provided insures a momentary energization of time element relay 2| by the closure of switch 39.

The closure of contacts 29 of time element relay 30 connects the operating winding 2| 0| contactor 2i across the source of control voltage 22 through conductors 21 and 28, contacts 2| of time element relay 3| and conductor 2|. Thus, depending on the delayed opening characteristics of the time element relay 3|, contactor 2| is energized for a predetermined period oi time.

When energized, contactor 2| closes its contacts 2| connecting the welding circuit i2, i2 to the source of supply II. If during the time that contacts 2| of the contactor 2| are closed the welding operator initiates a welding arc and proceeds to weld, minimum voltage relay 42 will close its contacts 4| and connect the operating winding 32 of time element relay 3| across the source of control voltage through conductors 21 and 33, contacts 4| 0! relay 42 and conductor 43. The reenergization of time element relay 30 will maintain its contacts 2! closed, and consequently, the energization of contactor 2| which will maintain its contacts closed so long as the welding operation proceeds. I! the welding arc is interrupted or goes out, maximum voltage relay 46 opens its contacts 45, deenergizes the minimum voltage relay 42 which opens its contacts 4|, thus deenergizing the time element relay 3|. Unless the arc is restruck within the time delay opening period of the relay 30, contactor 2| will become deenergized opening its contacts 2| and thereby disconnecting the welding circuit i2, I! from the source of supply i8.

It will be noted that if during the period that the welding circuit i2, II is energized, the operator touches electrode Iii to the work thus shorting the arc welding circuit, minimum voltage relay 42 will not be energized to close its contacts 4| and after a period of time determined by the delayed opening characteristics of relay 30, the arc welding circuit I2, I! will be disconnected from the source by the opening of contacts 29 of relay 3| which deenergizes the contactor 2| causing it to open its contacts 20.

If the welding circuit has been deenergized through the operation of either the maximum voltage relay 46 or the minimum voltage relay 42 and the consequent opening, after a predetermined time, of relay 3|, it cannot again be reenergized without again closing switch 2| to establish a sequence or operation such as above described. -It will also be noted that due to the action of the auxiliary control relay 3|, maintaining the switch 3| closed has no eifect on the operation of time element relay 2| and the consequent operation of the system. In fact, before the time element relay 3| may again be reenergized preparatory to initiating another welding operation, the switch 2| must be opened and again closed if it has been held closed.

The embodiment of our invention shown in Fig. 2 is quite similar to that shown in Fig. 1 except that the arc welding circuit operates at a reduced open circuit voltage when switch 2| is closed preparatory to initiating a welding operation. This reduced voltage will supply a current suflicient to produce an are that ionires the gap between the electrode and the work without causing the electrode to stick to the work when it is brought into engagement therewith. This modification of Fig. 1 is obtained by connecting the arc welding circuit to the source of supply through a voltage reducing means and simultaneously rendering the maximum voltage relay responsive to the reduced voltage of the arc welding circuit resulting from this connection.

In Fig. 2 those parts of the control system corresponding to those previously described in connection with Fig. 1 have been identified by like reference numerals. The voltage reducing means connected between the welding circuit i2, i8 and the source of supply consists of the operating winding 4| of a relay 0. The impedance of this winding is matched to the exciting current of the welding transformer so that its secondary voltage is reduced the desired amount. As shown in Fig. 2, it is connected in shunt to the contacts 2| of contactor 2| through a circuit including contacts 5| of a relay whose operating winding I2 is connected across the control voltage 22 through the contacts 2| of switch 2|.

The operating characteristics of relay 4| are such that when its winding 4| is connected to the source of supply l| in circuit with the primary II of the welding transformer, it closes its contacts 5| which are in shunt to a voltage reducer |4 connected in circuit with the operating winding 41 of maximum voltage relay 4|. When the operating winding 4| of relay is deenergized by the closing of contacts 2| of contactor 2|, voltage reducer I4 is again inserted in circuit with the operating winding 41 of maximum voltage relay 4|. This restores the normal operating characteristics of maximum voltage relay 4| so that it opens its contacts 4| at a voltage slightly above the maximum desired arc welding voltage. In the arrangement illustrated, the voltage reducer has been illustrated as a resistor but it may take other desired forms.

The operation of this system is as follows: When the operator is ready to start a welding operation, he closes the switch 2|. This energizes the operating winding 52 of relay Ii by connecting it across the source of control voltage 22 through the contacts 2| of switch 3|. Relay thus closes its contacts 5| connecting the operating winding 4| oi relay 4| across the contacts 2| 0| contactor 2|. So long as the operator maintains the switch 3| closed, a reduced voltage appears across the arc welding circuit l2, II which is connected through the welding transformer and the operating winding 4| of relay 4| to the source of supply II. This connection causes relay 4| to close its contacts 52 shunting resistor the pe ng Winding 41 of maximum voltage relay 4| which will consequently open its contacts 4| in response to the reduced open circuit voltage in the welding circuit i2, i3. As soon as the operator touches the electrode in to-the work H, maximum voltage relay 46 is deenergized closing its contacts 45, thus establishing an energizing circuit for the operating winding 44 of minimum voltage relay 42. When the operator withdraws the electrode H) from the work I l striking an ionizing arc with the reduced voltage available in the welding circuit l2, l3, the minimum voltage relay 42 closes its contacts 4| thus energizing the operating winding 32 of time element relay 30 through a circuit including conductors 21 and 33, contacts 4| of minimum voltage relay 42, and conductor 43. This causes time element relay 30 to close its contacts 29, thus energizing the operating winding 26 of contactor 2| from the source of control voltage 22 through a circuit including conductors 21 and 28, contacts 29 of time element relay 30 and conductor 3|. Contactor 2| thus closes its contacts 20 connecting the weldingcircuit I2, I3 through the welding transformer it directly to the source of supply l8 for supplying normal arc welding current and voltage thereto. The closure of contacts 20 of contactor2l short circuits the operating winding 48 of relay 49 which is thus deenergized opening its contacts 53 and inserting resistor 54 in circuit with the operating winding 41 of maximum voltage relay 48. Thereafter the system operates in the manner above described in connection with Fig. 1.

In the system of Fig. 2, it will be noted that before welding a reduced open circuit voltage. is supplied to the arc welding circuit I2, i3 so long as the switch 38 is closed and that this reduced open circuit voltage is not changed to the normal open circuit voltage until after the electrode H) has been touched to the work I and withdrawn therefrom to strike an ionizing are which is immediately converted into a power arc upon the operation of contactor 2|. After welding has once progressed, however, full open circuit voltage is available for an interval of time determined by time element relay 30 so that the operator may restrike his arc with full open circuit voltage when the electrode is hot. As previously pointed out, the low open circuit voltage available before initiating the welding arc minimizes the possibility of the electrode freezing to the work when the operator touches it to the work at the beginning of a welding operation.

The push button switch 39 may be located on the electrode holder M or connected through a separate control cable extending from the control panel to the welders station. It may, of course, be located directly on the control panel.

Although our invention has been described above in connection with alternating current arc welding systems, it is of course apparent that it is equally applicable to direct current arc welding systems. These systems may be variously modified without departing from the spirit and scope of our invention. For example, relays of different constructions controlling connections differently arranged may be used instead of those illustrated. In fact, electric valve circuits may be substituted for some or all of the electromagnetic relays and switches above described without departing from our invention. It is also apparent that parts of the systems described may be omitted by incorporating their function in the remaining parts of the systems. We aim, consequently, to cover by the appended claims all those modifications which fall within the true spirit and scope of our invention.

What we claim as new and desire to secure by Letters Patent of. the United States, is:

1. An arc welding system comprising a source of supply, an arc welding circuit, and means responsive to the operation of maximum and minimum voltage relays connected to be responsive to the voltage of said'arc welding circuit for controlling the connection of said arc welding circuit with said source of supply.

2. An arc welding system comprising a source of supply, an arc welding circuit, means including a time element relay for connecting said arc welding circuit to said source of supply and for maintaining said connection for a predetermined period of time after said time element relay ha been operated, and means including maximum and minimum voltage relays connected to be responsive to the voltage of said arc welding circuit for controlling the operation of said time element relay.

3. An arc welding system comprising a source of supply, an arc welding circuit, means for connecting said arc welding circuit with said source of supply for a predetermined period of time, and means responsive to predetermined maximum and minimum voltage values of said arc welding circuit for maintaining the connection of said arc welding circuit with said source of supplywhile the voltage of said welding circuit is between said maximum and minimum values.

4. An arc welding system comprising a source of supply, an arc welding circuit, means for connecting said arc welding circuit with said source of supply for a predetermined period of time, and means responsive to predetermined maximum and minimum voltage values of said arc welding circuit for maintaining the connection of said arc welding circuit with said source of supply while the voltage of said welding circuit is between said maximum and minimum values and for a predetermined period of time after the voltage of said welding circuit changes to a value greater or less than said maximum and minimum values.

5. An arc welding system comprising a source of supply, an arc welding circuit, means includin a time element relay for connecting said welding circuit with said source of supply and for maintaining said connection for a predetermined period of time after said time element relay is deenergized, switching means for momentarily energizing said time element relay, and means including maximum and minimum voltage relays connected to be responsive to the voltage of said arc welding circuit for controlling independently of said switching means the energization of said time element relay.

6. An arc welding system comprising a source of supply, an arc welding circuit, means including a time element relay for connecting said welding circuit with said source of supply and for maintaining said connection for a predetermined period of time after said time element relay is deenergized, means including a. switch and an auxiliary control relay for momentarily energizing said time element relay, and means including relays responsive to predetermined maximum and minimum values of voltages in said welding circuit for maintaining the energization ,of said time element relay so long as the voltage of said welding circuit is between said maximum and minimum values of voltage.

'7. An arc welding system comprising a source of supply, an arc welding circuit, means including maximum and minimum voltage relays connected to be responsive to the voltage of said arc welding circuit for controlling the direct connection of said arc welding circuit to said source of supply, and means for connecting said arc welding circuit to said source supply through a voltage reducing means and simultaneously rendering said maximum voltage relay responsive to the reduced voltage oi said arc welding circuit resulting from said connection.

8. An arc welding system comprising a source of supply, an arc welding circuit, means including a time element relay for completing a normal operating connection between said are and said source of supply and for maintaining said connection for a predetermined period 01' time after said time element relay is deenergized,means including relays responsive to predetermined maximum and minimum voltage values of said arc welding circuit for maintaining the energization of said time element relay so long as the voltage of said arc welding circuit is between said maximum and minimum voltage values, means for connecting said welding circuit to said source of supply through a winding of sumcient impedance to reduce the normal'operating open circuit voltage oi. said welding circuit to a predetermined value, and means responsive to the energization of said winding for rendering said maximum voltage relay responsive to the reduced open circuit voltage oi said arc welding circuit resulting from the connection of said impedance winding. 7

9. An arc welding system comprising a source of supply, an arc welding circuit, means including a time element relay for completing a normal operating connection between said arc welding circuit and said source of supply and for maintaining said connection (or a predetermined period 01' time after said time element relay is deenergired, means including relays responsive to predetermined maximum and minimum voltage values of said arc welding circuit for maintaining the energization of said time element relay so long as the normal operating voltage of said arc welding circuit is between said maximum and minimum voltage-values, a voltage reducer for changing the calibration of said maximum voltage relay from operation at a reduced open circuit voltage to operation at said predetermined maximum normal open circuit voltage, a voltage reducing relay having contacts shunting said voltage reducer and a winding of sumcient impedance to secure a desired reduction of the normal operating voltage between said source of supply and said welding circuit, and means for connecting said welding circuit to said source 01' supply through the winding of said voltage reducing relay to reduce the open circuit voltage or said welding circuit and to operate said relay to close its contacts and shunt said voltage re- JAMES 'r. cam. JASPER, E. ANDERSON.

'ducer. 

